WO2024105324A1 - Method for manufacturing a vane - Google Patents

Method for manufacturing a vane Download PDF

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Publication number
WO2024105324A1
WO2024105324A1 PCT/FR2023/051764 FR2023051764W WO2024105324A1 WO 2024105324 A1 WO2024105324 A1 WO 2024105324A1 FR 2023051764 W FR2023051764 W FR 2023051764W WO 2024105324 A1 WO2024105324 A1 WO 2024105324A1
Authority
WO
WIPO (PCT)
Prior art keywords
blade
advantageously
bonding layer
protective shield
particles
Prior art date
Application number
PCT/FR2023/051764
Other languages
French (fr)
Inventor
Anthony GRUNENWALD
Pierre-Antoine Bossan
Aurélien JOULIA
Sophie SENANI
Serge Georges Vladimir Selezneff
Original Assignee
Safran Aircraft Engines
Safran
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Safran Aircraft Engines, Safran filed Critical Safran Aircraft Engines
Publication of WO2024105324A1 publication Critical patent/WO2024105324A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/026—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/028—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • F05D2230/311—Layer deposition by torch or flame spraying
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • F05D2230/312—Layer deposition by plasma spraying
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603—Composites; e.g. fibre-reinforced

Definitions

  • TITLE PROCESS FOR MANUFACTURING A BLADE
  • the invention relates to the field of manufacturing processes for blades for aircraft turbomachines.
  • the invention relates more particularly to the field of manufacturing blades comprising a blade made of composite material and a protective shield arranged on the blade.
  • An aircraft turbomachine typically comprises an engine comprising, upstream and downstream in the direction of gas flow, a mobile fan rotating around a longitudinal axis, a low pressure compressor and a high pressure compressor, a combustion chamber , a high pressure turbine and a low pressure turbine and a gas exhaust nozzle.
  • the blower allows the suction of an air flow divided into a primary flow and a secondary flow.
  • the primary flow passes through a primary vein of the turbomachine while the secondary flow is directed towards a secondary vein surrounding the primary vein.
  • the primary flow is compressed within the compressors.
  • the compressed air is then mixed with fuel and burned within the combustion chamber.
  • the gases resulting from combustion pass through the turbines then escape through the nozzle, the section of which allows the acceleration of these gases to generate propulsion.
  • the components of the turbomachine such as the fan, compressors or turbines include blades which make it possible to exert an action on the air flow.
  • compressor blades make it possible to compress the primary air flow and the fan blades compress the secondary air flow.
  • a blade comprises a blade which has an aerodynamic shape and thus comprises an intrados face and an extrados face connected to the intrados face by a leading edge and a trailing edge.
  • the blade is made of a composite material.
  • the composite material of the blade includes reinforcing fibers embedded in a polymer matrix.
  • cover the leading edge with a protective shield.
  • the protective shield has a dihedral shape comprising a first side fin and a second side fin connected by a core.
  • the core covers the leading edge and the first lateral fin extends on the intrados face and the second lateral fin extends on the extrados face.
  • the protective shield is typically glued to the blade.
  • the blade further comprises a connecting layer arranged between the blade and the protective shield.
  • the bonding layer typically comprises a polymeric material such as an epoxy resin.
  • a process for manufacturing the aforementioned blade comprises the following steps:
  • the process then includes a step of pairing and bonding the protective shield to the blade.
  • the step of pairing the protective shield which consists of attaching the protective shield to the blade is carried out in a manner manual so that, guaranteeing the precision of the assembly of the blade and the repeatability of this step, require perfect mastery of the manufacturing process to limit defects on the protective shield or the blade and therefore the rejection of these pieces.
  • the invention proposes a method of manufacturing a blade for an aircraft turbomachine, the method comprising the following chronological steps:
  • the thermal spray process makes it possible to form coatings of complex geometry in a precise and repeatable manner, reducing the risk of defects in the protective shield and its disposal.
  • the thermal spraying process it is possible to dispense with a step of manufacturing the protective shield in favor of a step of forming the protective shield directly on the blade. This also makes it possible to dispense with a step of pairing the shield on the blade, thus making it possible to simplify the process of assembling a blade and a protective shield and to reduce assembly defects of the blade. 'dawn.
  • the thermal spraying process also allows the implementation of material variability for the protective shield which is not offered by other shield manufacturing processes.
  • the method comprises, after the step of forming the protective shield, a step of heat treatment of the bonding layer.
  • the heat treatment stage allows the polymerization of the bonding layer and subsequently, the fixation by gluing of the protective shield on the blade.
  • the invention may include one or more of the following characteristics, taken in isolation from each other or in combination with each other:
  • - thermal spraying is carried out with a powder comprising metallic or ceramic particles or a mixture of these;
  • the particles have a size (d90) between 5 pm and 200 pm, advantageously between 10 pm and 150 pm;
  • the particles have a size (d10) between 0.05 pm and 50 pm, advantageously between 0.1 pm and 20 pm;
  • the bonding layer has a thickness of between 50 pm and 500 pm, advantageously between 80 pm and 400 pm;
  • step (d) is carried out at a temperature between 100°C and 200°C, advantageously between 140°C and 190°C;
  • step (d) the blade is placed in a heating device such as an oven, an oven or an autoclave;
  • the method comprises between steps (b) and (c) a step (f) of pre-heat treatment of the bonding layer;
  • step (f) is carried out at a temperature less than or equal to 150°C, advantageously less than or equal to 130°C, or advantageously even less than 100°C;
  • the method comprises after step (d), a step (e) of machining the protective shield; -- step (c) of thermal projection is carried out along the leading edge and/or the trailing edge of the blade.
  • Figure 1 is a schematic view in longitudinal section of a half-turbomachine of aircraft
  • Figure 2 is a schematic perspective view of a blade fitted to the turbomachine of Figure 1
  • Figure 3 is a cross-sectional view of the blade of Figure 2
  • Figure 4 is another schematic view in section of the blade of Figure 2
  • Figure 5 is a schematic view of a manufacturing process according to the invention
  • Figure 6 is a schematic view of the manufacturing process according to an advantageous embodiment of the invention.
  • FIG. 1 An example of an aircraft turbomachine 1 according to the invention is shown in Figure 1.
  • the turbomachine 1 extends around and along a longitudinal axis A.
  • upstream is defined in relation to the direction of gas circulation in the turbomachine 1 along the longitudinal axis A.
  • the turbomachine 1 extends around a longitudinal axis A. It comprises from upstream to downstream in the direction of gas flow F along the axis longitudinal A, a fan 2, at least one compressor such as a low pressure compressor 3 and a high pressure compressor 4, a combustion chamber 5, at least one turbine 6 such as a high pressure turbine and a low pressure turbine, and a nozzle (not shown).
  • the rotor of the low pressure turbine is connected to the fan 2 and to the rotor of the low pressure compressor 3 by a low pressure shaft (not shown).
  • the rotor of the high pressure turbine is connected to the rotor of the high pressure compressor 4 by a high pressure shaft (not shown).
  • the turbomachine 1 also includes a rectifier 10.
  • the rectifier 10 is also included in The turbomachine 1.
  • the rectifier 10 makes it possible to straighten the flow at the exit of a rotor located upstream in order to provide maximum thrust at the exit of the turbomachine 1.
  • the rectifier 10 is located downstream of the blower 2 and makes it possible to straighten the secondary flow F2.
  • the blower 2 allows the suction of an air flow divided into a primary flow F1 and a secondary flow F2.
  • the primary flow F1 passes through a primary vein of the turbomachine 1 while the secondary flow F2 is directed towards a secondary vein surrounding the primary vein.
  • the primary flow F1 is compressed within the low pressure compressor 3 then the high pressure compressor 4.
  • the compressed air is then mixed with a fuel and burned within the combustion chamber 5.
  • the gases formed by the combustion pass through the turbine high pressure and the low pressure turbine.
  • the gases finally escape through the nozzle, the section of which allows the acceleration of these gases to generate propulsion.
  • the secondary flow F2 passes through the rectifier 10 which accelerates the circulation speed of the secondary flow F2 to generate propulsion.
  • the fan 2 or the rectifier 10 comprise blades 11.
  • the blades 11 fitted to the rectifier 10 are known by the English term “Outlet Guide Vane” (OGV).
  • OGV Outlet Guide Vane
  • the blades 11 are movable or fixed in rotation around the longitudinal axis A.
  • the blades 11 of the fan 11 are movable in rotation.
  • the blades 11 of the rectifier 10 are fixed.
  • the blades 11 extend radially relative to the longitudinal axis A.
  • each blade 11 comprises a blade 12 and a protective shield 14 arranged on the blade 12.
  • the blade 12 extends along an axis of elongation X.
  • the blade 12 has an aerodynamic profile.
  • the blade 12 thus comprises an extrados face 12e and an intrados face 12i connected by a leading edge 12a and a trailing edge 12b.
  • the blade 12 thus extends along a transverse axis Y between the leading edge 12a and the trailing edge 12b.
  • the blade 12 also extends longitudinally along the elongation axis X between a first end and a second end opposite the first end.
  • the blade 12 comprises a composite material.
  • the composite material comprises a polymeric matrix and a fibrous reinforcement embedded in the matrix.
  • the composite material is for example an organic matrix composite (CMO).
  • the matrix is for example a thermoplastic or thermosetting polymer matrix.
  • the thermosetting material is for example an epoxy polymer.
  • the fibrous reinforcement comprises fibers which are for example carbon fibers or glass fibers. The fibers are organized, for example, in the form of a fibrous preform.
  • the protective shield 14 is advantageously arranged on the leading edge 12a. It extends advantageously all along the leading edge 12a.
  • the protective shield 14 is advantageously made of metallic material.
  • the metallic material is for example titanium or an alloy such as steel, for example stainless steel or a nickel and cobalt alloy (NiCo), aluminum, silver, zinc, nickel, copper or a mixture of these.
  • the protective shield 14 is according to another example made of ceramic material. 11 is intended to protect the leading edge 12a from external shocks.
  • the protective shield 14 has an elongated dihedral shape. As better visible in Figure 3, the protective shield 14 has a V- or U-shaped cross section.
  • the protective shield 14 comprises a first side fin 14a and a second side fin 14b connected to the first side fin 14a by a soul 14d.
  • the first and second side fins 14a, 14b define between them a cavity in which the leading edge 12a is arranged.
  • the first lateral fin 14a has a first free longitudinal end and the second lateral fin 14b has a second free longitudinal end which are opposite the core 14j.
  • the free longitudinal ends extend along the blade 12.
  • the free longitudinal ends extend respectively on the intrados face 12i and the extrados face 12b of the blade 12.
  • the thickness of the protective shield 14 is variable.
  • the thickness of the core 14j is greater than the thicknesses of the first and second side fins 14a, 14b.
  • the thickness of the first and second side fins 14a, 14b decreases towards the trailing edge 12b of the blade 12.
  • the first and second side fins 14a, 14b are tapered towards the trailing edge 12b of the blade 12. .
  • the protective shield 14 is arranged on the trailing edge 12b.
  • the blade 11 comprises two protective shields 14 arranged respectively on the leading edge 12a and the trailing edge 12b.
  • the protective shield 14 is very advantageously formed on the blade 12 by thermal spraying.
  • the blade 11 further comprises a connecting layer 16 arranged between the blade
  • the bonding layer 16 ensures adhesion of the protective shield 14 on the blade 12 without damaging the blade 12.
  • the connecting layer 16 is made of polymeric material.
  • the polymeric material is advantageously chosen from thermosetting polymers such as an epoxy, silicone or polyurethane polymer or thermoplastic polymers or even a mixture of these.
  • the epoxy polymer is for example the commercial material Redux® 322 from the company HEXCEL.
  • the bonding layer 16 is typically in the form of a film based on one of the materials mentioned.
  • the film is for example the commercial film AF191 or AF3109 from the company 3M.
  • the connecting layer 16 has a thickness of between 50 pm and 500 pm, even more advantageously between 80 pm and 400 pm.
  • the process includes the following chronological steps:
  • Step (a) can be carried out by molding such as resin transfer molding known by the acronym RTM for “Resin Transfer Molding” in English or draping.
  • Step (b) can be carried out by draping the film, or by manually applying the material of the bonding layer 16.
  • the thermal spraying process of step (c) is for example a flame spraying process, for example by high speed oxygen flame (HVOF for “High Velocity Oxy-Fuel” in English), by arc-wire , by suspension, by arc plasma, cold spray or any other applicable thermal spraying process.
  • HVOF high speed oxygen flame
  • Thermal spraying is carried out with a powder comprising particles of which at least 90% of these particles have a size (d90) between 5 pm and 200 pm, advantageously between 10 pm and 150 pm and preferably of which at most 10% of the particles have a size (d10) between 0.05 pm and 50 pm, advantageously between 0.1 pm and 20 p.m.
  • the powder comprises particles of which at least 90% of these particles have a size (d90) of 110 pm and of which at most 10% particles have a size (d10) of 10 pm.
  • the powder is in the form of a suspension comprising particles of which at least 90% of these particles have a size (d90) of 10 pm and of which at most 10% particles have a size (d10) of 0.1 pm.
  • the particles are particles of metal such as aluminum, silver, zinc, nickel, titanium, copper, an iron alloy, a metal alloy or ceramic particles such as particles non-oxide such as silicon carbide, or oxide particles such as aluminum oxide, zirconium oxide, silicon oxide, or even a mixture of particles.
  • metal such as aluminum, silver, zinc, nickel, titanium, copper, an iron alloy, a metal alloy or ceramic particles such as particles non-oxide such as silicon carbide, or oxide particles such as aluminum oxide, zirconium oxide, silicon oxide, or even a mixture of particles.
  • the thermal spraying step is carried out on a homogeneous bonding layer 16, which contributes to good adhesion of the protective shield 14 over the entire surface of the bonding layer 16.
  • Thermal projection step (c) is carried out along the leading edge 12a and/or along the trailing edge 12b of the blade 12.
  • Step (d) allows the polymerization of the bonding layer 16 and the consolidation of the interface between the bonding layer 16 and the functional layer formed by the coating 14.
  • Step (d) is preferably carried out for a duration greater than 10 min, greater than 15 min, greater than 20 min, greater than 30 min even more preferably between 45 min and 200 min.
  • the blade 11 is for example placed in a heating device such as an oven, an oven or an autoclave.
  • Machining step (e) can be chemical machining or mechanical machining such as cutting.
  • the method comprises between steps (b) and (c) a step (f) of thermal pre-treatment of the bonding layer 16.
  • This step can be carried out by heating the bonding layer 16 to a temperature less than or equal to 150°C for pre-polymerization, advantageously less than or equal to 130°C.
  • This thermal pretreatment step advantageously makes it possible to avoid the loss of the bonding layer 16 during step (c) of thermal spraying.
  • This same step (f) can be carried out at a temperature lower than 100°C to only increase the tackiness.
  • This step can be carried out in an oven or an autoclave or an oven. This step makes it possible to increase the adhesion force at the interface of the bonding layer 16 and the protective shield 14.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

The invention relates to a method for manufacturing a vane (11) for an aircraft turbine engine (1), comprising the following chronological steps: (a) providing a blade (12) comprising a suction face (12e) and a pressure face (12i) connected by a leading edge (12a) and a trailing edge (12b), the blade (12) comprising a composite material, (b) arranging a bonding layer (16) on the blade (12), the bonding layer (16) comprising a polymer material, the method being characterised in that it further comprises the following chronological steps performed after step (b): (c) forming a protective shield (14) on the blade (12) by thermal spraying, (d) optionally, heat-treating the bonding layer (16).

Description

DESCRIPTION DESCRIPTION
TITRE : PROCEDE DE FABRICATION D’UNE AUBE TITLE: PROCESS FOR MANUFACTURING A BLADE
Domaine technique de l'invention Technical field of the invention
L’invention concerne le domaine des procédés de fabrication des aubes pour les turbomachines d’aéronef. L’invention concerne plus particulièrement le domaine de fabrication des aubes comprenant une pale en matériau composite et un bouclier de protection agencé sur la pale. The invention relates to the field of manufacturing processes for blades for aircraft turbomachines. The invention relates more particularly to the field of manufacturing blades comprising a blade made of composite material and a protective shield arranged on the blade.
Arrière-plan technique Technical background
L’état de la technique est illustré par les documents US-A1 -2016/0305442 et FR-A1 -3008 109. The state of the art is illustrated by documents US-A1 -2016/0305442 and FR-A1 -3008 109.
Une turbomachine d’aéronef comprend typiquement un moteur comprenant d’amont en aval dans le sens d’écoulement des gaz, une soufflante mobile en rotation autour d’un axe longitudinal, un compresseur basse pression et un compresseur haute pression, une chambre de combustion, une turbine haute pression et une turbine basse pression et une tuyère d’échappement des gaz. An aircraft turbomachine typically comprises an engine comprising, upstream and downstream in the direction of gas flow, a mobile fan rotating around a longitudinal axis, a low pressure compressor and a high pressure compressor, a combustion chamber , a high pressure turbine and a low pressure turbine and a gas exhaust nozzle.
La soufflante permet l’aspiration d’un flux d’air se divisant en un flux primaire et un flux secondaire. Le flux primaire traverse une veine primaire de la turbomachine tandis que le flux secondaire est dirigé vers une veine secondaire entourant la veine primaire. The blower allows the suction of an air flow divided into a primary flow and a secondary flow. The primary flow passes through a primary vein of the turbomachine while the secondary flow is directed towards a secondary vein surrounding the primary vein.
Le flux primaire est comprimé au sein des compresseurs. L’air comprimé est ensuite mélangé à un carburant et brûlé au sein de la chambre de combustion. Les gaz issus de la combustion traversent les turbines puis s’échappent au travers de la tuyère dont la section permet l’accélération de ces gaz pour générer de la propulsion. The primary flow is compressed within the compressors. The compressed air is then mixed with fuel and burned within the combustion chamber. The gases resulting from combustion pass through the turbines then escape through the nozzle, the section of which allows the acceleration of these gases to generate propulsion.
Les composants de la turbomachine tels que la soufflante, les compresseurs ou les turbines comprennent des aubes qui permettent d’exercer une action sur le flux d’air. Par exemple, les aubes de compresseurs permettent de comprimer le flux d’air primaire et les aubes de la soufflante permettent de comprimer le flux d’air secondaire. The components of the turbomachine such as the fan, compressors or turbines include blades which make it possible to exert an action on the air flow. For example, compressor blades make it possible to compress the primary air flow and the fan blades compress the secondary air flow.
Une aube comprend une pale qui présente une forme aérodynamique et comprend ainsi une face intrados et une face extrados reliée à la face intrados par un bord d’attaque et un bord de fuite. Pour réduire le poids de l’aube, la pale est en un matériau composite. Le matériau composite de la pale comprend des fibres de renfort noyées dans une matrice polymérique. Afin de protéger la pale, notamment de soufflante, d’une dégradation provoquée par l’impact de corps étrangers et de l’érosion, il est connu de revêtir le bord d’attaque d’un bouclier de protection. Le bouclier de protection présente une forme de dièdre comprenant une première ailette latérale et une seconde ailette latérale reliées par une âme. L’âme recouvre le bord d’attaque et la première ailette latérale s’étend sur la face intrados et la seconde ailette latérale s’étend sur la face extrados. Le bouclier de protection est typiquement collé à la pale. A cet effet, l’aube comprend en outre une couche de liaison agencée entre la pale et le bouclier de protection. La couche de liaison comprend typiquement un matériau polymérique tel qu’une résine époxy. A blade comprises a blade which has an aerodynamic shape and thus comprises an intrados face and an extrados face connected to the intrados face by a leading edge and a trailing edge. To reduce the weight of the blade, the blade is made of a composite material. The composite material of the blade includes reinforcing fibers embedded in a polymer matrix. In order to protect the blade, in particular the fan blade, from degradation caused by the impact of foreign bodies and erosion, it is known to cover the leading edge with a protective shield. The protective shield has a dihedral shape comprising a first side fin and a second side fin connected by a core. The core covers the leading edge and the first lateral fin extends on the intrados face and the second lateral fin extends on the extrados face. The protective shield is typically glued to the blade. For this purpose, the blade further comprises a connecting layer arranged between the blade and the protective shield. The bonding layer typically comprises a polymeric material such as an epoxy resin.
Un procédé de fabrication de l’aube précitée comprend les étapes suivantes : A process for manufacturing the aforementioned blade comprises the following steps:
- fabrication de la pale, - manufacturing of the blade,
- fabrication du bouclier de protection. - manufacturing of the protective shield.
Le procédé comprend ensuite une étape d’appairage et de collage du bouclier de protection sur la pale. The process then includes a step of pairing and bonding the protective shield to the blade.
Un tel procédé de fabrication ne procure par entière satisfaction. En effet, l’étape de fabrication du bouclier de protection présente des défis car la configuration du bouclier de protection est complexe. Cette étape est par conséquent fastidieuse. Par ailleurs, les tolérances de fabrication sont faibles et il est difficile d’assurer la répétabilité de cette étape. Such a manufacturing process does not provide complete satisfaction. Indeed, the manufacturing stage of the protective shield presents challenges because the configuration of the protective shield is complex. This step is therefore tedious. Furthermore, manufacturing tolerances are low and it is difficult to ensure the repeatability of this step.
Par ailleurs, l’étape d’appairage du bouclier de protection qui consiste à rapporter le bouclier de protection sur la pale est réalisée de manière manuelle si bien que, garantir la précision de l’assemblage de l’aube et la répétabilité de cette étape, requièrent une maitrise parfaite du procédé de fabrication pour limiter les défauts sur le bouclier de protection ou l’aube et donc le rebus de ces pièces. Furthermore, the step of pairing the protective shield which consists of attaching the protective shield to the blade is carried out in a manner manual so that, guaranteeing the precision of the assembly of the blade and the repeatability of this step, require perfect mastery of the manufacturing process to limit defects on the protective shield or the blade and therefore the rejection of these pieces.
Par conséquent, il existe un besoin de fournir un procédé simple à mettre en œuvre, pour la fabrication d’une aube pour une turbomachine d’aéronef, comprenant une pale en matériau composite, qui soit résistante aux chocs et à l’érosion. Consequently, there is a need to provide a method that is simple to implement for the manufacture of a blade for an aircraft turbomachine, comprising a blade made of composite material, which is resistant to shock and erosion.
Résumé de l'invention Summary of the invention
A cet effet, l’invention propose un procédé de fabrication d’une aube pour une turbomachine d’aéronef, le procédé comprenant les étapes chronologiques suivantes : To this end, the invention proposes a method of manufacturing a blade for an aircraft turbomachine, the method comprising the following chronological steps:
(a) fournir une pale comprenant une face extrados et une face intrados reliées par un bord d’attaque et un bord de fuite, la pale comprenant un matériau composite, (a) provide a blade comprising an extrados face and an intrados face connected by a leading edge and a trailing edge, the blade comprising a composite material,
(b) agencer une couche de liaison sur la pale, la couche de liaison comprenant un matériau polymérique. (b) arranging a bond layer on the blade, the bond layer comprising a polymeric material.
Le procédé est notamment remarquable en ce qu’il comprend en outre les étapes chronologiques suivantes après l’étape (b) : The process is particularly remarkable in that it further comprises the following chronological steps after step (b):
(c) former un bouclier de protection sur la pale par projection thermique,(c) forming a protective shield on the blade by thermal spraying,
(d) traiter thermiquement la couche de liaison. (d) heat treating the bond layer.
Le procédé de projection thermique permet de former des revêtements de géométrie complexe de manière précise et répétable réduisant ainsi les risques de défauts du bouclier de protection et sa mise au rebut. The thermal spray process makes it possible to form coatings of complex geometry in a precise and repeatable manner, reducing the risk of defects in the protective shield and its disposal.
En outre, grâce au procédé de projection thermique il est possible de s’affranchir d’une étape de fabrication du bouclier de protection au profit d’une étape de formation du bouclier de protection directement sur la pale. Ceci permet en outre de s’affranchir d’une étape d’appairage du bouclier sur la pale permettant ainsi de simplifier le procédé d’assemblage d’une aube et d’un bouclier de protection et de réduire les défauts d’assemblage de l’aube. Le procédé de projection thermique permet en plus la mise en œuvre d’une variabilité de matériaux pour le bouclier de protection qui n’est pas offerte par les autres procédés de fabrication du bouclier. In addition, thanks to the thermal spraying process it is possible to dispense with a step of manufacturing the protective shield in favor of a step of forming the protective shield directly on the blade. This also makes it possible to dispense with a step of pairing the shield on the blade, thus making it possible to simplify the process of assembling a blade and a protective shield and to reduce assembly defects of the blade. 'dawn. The thermal spraying process also allows the implementation of material variability for the protective shield which is not offered by other shield manufacturing processes.
Le procédé comprend après l’étape de formation du bouclier de protection une étape de traitement thermique de la couche de liaison. L’étape de traitement thermique permet la polymérisation de la couche de liaison et par suite, la fixation par collage du bouclier de protection sur la pale. The method comprises, after the step of forming the protective shield, a step of heat treatment of the bonding layer. The heat treatment stage allows the polymerization of the bonding layer and subsequently, the fixation by gluing of the protective shield on the blade.
L’invention peut comprendre une ou plusieurs des caractéristiques suivantes, prises isolément les unes des autres ou en combinaison les unes avec les autres : The invention may include one or more of the following characteristics, taken in isolation from each other or in combination with each other:
- la projection thermique est réalisée avec une poudre comprenant des particules métalliques, céramiques ou un mélange de celles-ci ; - thermal spraying is carried out with a powder comprising metallic or ceramic particles or a mixture of these;
- au moins 90% des particules présentent une taille (d90) comprise entre 5 pm et 200 pm, avantageusement comprise entre 10 pm et 150 pm ; - at least 90% of the particles have a size (d90) between 5 pm and 200 pm, advantageously between 10 pm and 150 pm;
- au plus 10% des particules présentent une taille (d10) comprise entre 0,05 pm et 50 pm, avantageusement comprise entre 0,1 pm et 20 pm ; - at most 10% of the particles have a size (d10) between 0.05 pm and 50 pm, advantageously between 0.1 pm and 20 pm;
- la couche de liaison présente une épaisseur comprise entre 50 pm et 500 pm, avantageusement entre 80 pm et 400 pm ; - the bonding layer has a thickness of between 50 pm and 500 pm, advantageously between 80 pm and 400 pm;
- l’étape (d) est réalisée à une température comprise entre 100 °C et 200 °C, avantageusement entre 140 °C et 190 °C ; - step (d) is carried out at a temperature between 100°C and 200°C, advantageously between 140°C and 190°C;
- à l’étape (d) l’aube est placée dans un dispositif de chauffage tel qu’une étuve, un four ou un autoclave ; - in step (d) the blade is placed in a heating device such as an oven, an oven or an autoclave;
- le procédé comprend entre les étapes (b) et (c) une étape (f) de pré traitement thermique de la couche de liaison ; - the method comprises between steps (b) and (c) a step (f) of pre-heat treatment of the bonding layer;
- l’étape (f) est réalisée à une température inférieure ou égale à 150 °C, avantageusement inférieure ou égale à 130 °C, ou avantageusement encore inférieure à 100°C ; - step (f) is carried out at a temperature less than or equal to 150°C, advantageously less than or equal to 130°C, or advantageously even less than 100°C;
- le procédé comprend après l’étape (d), une étape (e) d’usinage du bouclier de protection ; -- l’étape (c) de projection thermique est réalisée le long du bord d’attaque et/ou du bord de fuite de la pale. - the method comprises after step (d), a step (e) of machining the protective shield; -- step (c) of thermal projection is carried out along the leading edge and/or the trailing edge of the blade.
Brève description des figures Brief description of the figures
D’autres caractéristiques et avantages ressortiront de la description qui suit d’un mode de réalisation non limitatif de l’invention en référence aux dessins annexés sur lesquels : la figure 1 est une vue schématique en coupe longitudinale d’une demi- turbomachine d’aéronef, la figure 2 est une vue schématique en perspective d’une aube équipant la turbomachine de la figure 1 , la figure 3 est une vue en coupe transversale de l’aube de la figure 2, la figure 4 est une autre vue schématique en coupe de l’aube de la figure 2, la figure 5 est une vue schématique d’un procédé de fabrication selon l’invention, la figure 6 est une vue schématique du procédé de fabrication selon un mode de réalisation avantageux de l’invention. Other characteristics and advantages will emerge from the following description of a non-limiting embodiment of the invention with reference to the appended drawings in which: Figure 1 is a schematic view in longitudinal section of a half-turbomachine of aircraft, Figure 2 is a schematic perspective view of a blade fitted to the turbomachine of Figure 1, Figure 3 is a cross-sectional view of the blade of Figure 2, Figure 4 is another schematic view in section of the blade of Figure 2, Figure 5 is a schematic view of a manufacturing process according to the invention, Figure 6 is a schematic view of the manufacturing process according to an advantageous embodiment of the invention.
Description détaillée de l'invention Detailed description of the invention
Un exemple de turbomachine 1 d’aéronef selon l’invention est représenté sur la figure 1 . La turbomachine 1 s’étend autour et le long d’un axe longitudinal A. An example of an aircraft turbomachine 1 according to the invention is shown in Figure 1. The turbomachine 1 extends around and along a longitudinal axis A.
Dans la présente demande, les termes « axial », « axialement >>, « radial >> et « radialement » sont définis par rapport à l’axe longitudinal A. In the present application, the terms “axial”, “axially”, “radial” and “radially” are defined with respect to the longitudinal axis A.
Les termes « amont », « aval » sont définis par rapport au sens de circulation des gaz dans la turbomachine 1 suivant l’axe longitudinal A. The terms “upstream”, “downstream” are defined in relation to the direction of gas circulation in the turbomachine 1 along the longitudinal axis A.
Les termes « interne », « intérieur », « externe », « extérieur »,The terms “internal”, “interior”, “external”, “exterior”,
« extérieurement » sont définis par rapport à l’éloignement de l’axe longitudinal X le long d’un axe radial perpendiculaire à l’axe longitudinal A.“externally” are defined in relation to the distance from the longitudinal axis X along a radial axis perpendicular to the longitudinal axis A.
La turbomachine 1 s’étend autour d’un axe longitudinal A. Elle comprend d’amont en aval dans le sens d’écoulement des gaz F le long de l’axe longitudinal A, une soufflante 2, au moins un compresseur tel qu’un compresseur basse pression 3 et un compresseur haute pression 4, une chambre de combustion 5, au moins une turbine 6 telle qu’une turbine haute pression et une turbine basse pression, et une tuyère (non représentée).The turbomachine 1 extends around a longitudinal axis A. It comprises from upstream to downstream in the direction of gas flow F along the axis longitudinal A, a fan 2, at least one compressor such as a low pressure compressor 3 and a high pressure compressor 4, a combustion chamber 5, at least one turbine 6 such as a high pressure turbine and a low pressure turbine, and a nozzle (not shown).
Le rotor de la turbine basse pression est relié à la soufflante 2 et au rotor du compresseur basse pression 3 par un arbre basse pression (non représenté). Le rotor de la turbine haute pression est quant à lui relié au rotor du compresseur haute pression 4 par un arbre haute pression (non représenté). The rotor of the low pressure turbine is connected to the fan 2 and to the rotor of the low pressure compressor 3 by a low pressure shaft (not shown). The rotor of the high pressure turbine is connected to the rotor of the high pressure compressor 4 by a high pressure shaft (not shown).
La turbomachine 1 comprend par ailleurs un redresseur 10. Le redresseurThe turbomachine 1 also includes a rectifier 10. The rectifier
10 permet de redresser le flux à la sortie d’un rotor situé en amont afin de fournir une poussée maximale à la sortie de la turbomachine 1 . Sur l’exemple particulier de la figure 1 , le redresseur 10 est situé en aval de la soufflante 2 et permet de redresser le flux secondaire F2. 10 makes it possible to straighten the flow at the exit of a rotor located upstream in order to provide maximum thrust at the exit of the turbomachine 1. In the particular example of Figure 1, the rectifier 10 is located downstream of the blower 2 and makes it possible to straighten the secondary flow F2.
La soufflante 2 permet l’aspiration d’un flux d’air se divisant en un flux primaire F1 et un flux secondaire F2. Le flux primaire F1 traverse une veine primaire de la turbomachine 1 tandis que le flux secondaire F2 est dirigé vers une veine secondaire entourant la veine primaire. The blower 2 allows the suction of an air flow divided into a primary flow F1 and a secondary flow F2. The primary flow F1 passes through a primary vein of the turbomachine 1 while the secondary flow F2 is directed towards a secondary vein surrounding the primary vein.
Le flux primaire F1 est comprimé au sein du compresseur basse pression 3 puis du compresseur haute pression 4. L’air comprimé est ensuite mélangé à un carburant et brûlé au sein de la chambre de combustion 5. Les gaz formés par la combustion traversent la turbine haute pression et la turbine basse pression. Les gaz s’échappent enfin au travers de la tuyère dont la section permet l’accélération de ces gaz pour générer de la propulsion. Le flux secondaire F2 traverse le redresseur 10 qui accélère la vitesse de circulation du flux secondaire F2 pour générer de la propulsion. The primary flow F1 is compressed within the low pressure compressor 3 then the high pressure compressor 4. The compressed air is then mixed with a fuel and burned within the combustion chamber 5. The gases formed by the combustion pass through the turbine high pressure and the low pressure turbine. The gases finally escape through the nozzle, the section of which allows the acceleration of these gases to generate propulsion. The secondary flow F2 passes through the rectifier 10 which accelerates the circulation speed of the secondary flow F2 to generate propulsion.
La soufflante 2 ou le redresseur 10 comprennent des aubes 11. Les aubesThe fan 2 or the rectifier 10 comprise blades 11. The blades
11 équipant le redresseur 10 sont connues sous le terme anglais « Outlet Guide Vane » (OGV). Les aubes 11 sont mobiles ou fixes en rotation autour de l’axe longitudinal A. Typiquement, les aubes 11 de la soufflante 11 sont mobiles en rotation. Les aubes 11 du redresseur 10 sont fixes. Les aubes 11 s’étendent radialement par rapport à l’axe longitudinal A.11 fitted to the rectifier 10 are known by the English term “Outlet Guide Vane” (OGV). The blades 11 are movable or fixed in rotation around the longitudinal axis A. Typically, the blades 11 of the fan 11 are movable in rotation. The blades 11 of the rectifier 10 are fixed. The blades 11 extend radially relative to the longitudinal axis A.
En référence à la figure 2, chaque aube 11 comprend une pale 12 et un bouclier de protection 14 agencé sur la pale 12. With reference to Figure 2, each blade 11 comprises a blade 12 and a protective shield 14 arranged on the blade 12.
La pale 12 s’étend selon un axe d’allongement X. L’axe d’allongement X de la pale 12 s’étend radialement par rapport à l’axe longitudinal A de la turbomachine 1 après montage de l’aube 11 sur la turbomachine 1. La pale 12 présente un profil aérodynamique. La pale 12 comprend ainsi une face extrados 12e et une face intrados 12i reliées par un bord d’attaque 12a et un bord de fuite 12b. La pale 12 s’étend ainsi selon un axe transversal Y entre le bord d’attaque 12a et le bord de fuite 12b. The blade 12 extends along an axis of elongation X. The axis of elongation turbomachine 1. The blade 12 has an aerodynamic profile. The blade 12 thus comprises an extrados face 12e and an intrados face 12i connected by a leading edge 12a and a trailing edge 12b. The blade 12 thus extends along a transverse axis Y between the leading edge 12a and the trailing edge 12b.
La pale 12 s’étend par ailleurs longitudinalement selon l’axe d’allongement X entre une première extrémité et une seconde extrémité opposée à la première extrémité. The blade 12 also extends longitudinally along the elongation axis X between a first end and a second end opposite the first end.
La pale 12 comprend un matériau composite. Le matériau composite comprend une matrice polymérique et un renfort fibreux noyé dans la matrice. Le matériau composite est par exemple un composite à matrice organique (CMO). La matrice est par exemple une matrice polymérique thermoplastique ou thermodurcissable. Le matériau thermodurcissable est par exemple un polymère époxyde. Le renfort fibreux comprend des fibres qui sont par exemple des fibres de carbone ou des fibres de verre. Les fibres sont organisées par exemple sous la forme d’une préforme fibreuse. The blade 12 comprises a composite material. The composite material comprises a polymeric matrix and a fibrous reinforcement embedded in the matrix. The composite material is for example an organic matrix composite (CMO). The matrix is for example a thermoplastic or thermosetting polymer matrix. The thermosetting material is for example an epoxy polymer. The fibrous reinforcement comprises fibers which are for example carbon fibers or glass fibers. The fibers are organized, for example, in the form of a fibrous preform.
Le bouclier de protection 14 est avantageusement agencé sur le bord d’attaque 12a. Il s’étend avantageusement tout le long du bord d’attaque 12a. Le bouclier de protection 14 est avantageusement en matériau métallique. Le matériau métallique est par exemple du titane ou un alliage tel qu’un acier, par exemple un acier inoxydable ou un alliage de nickel et de cobalt (NiCo), un aluminium, de l’argent, du zinc, du nickel, du cuivre ou un mélange de ceux-ci. The protective shield 14 is advantageously arranged on the leading edge 12a. It extends advantageously all along the leading edge 12a. The protective shield 14 is advantageously made of metallic material. The metallic material is for example titanium or an alloy such as steel, for example stainless steel or a nickel and cobalt alloy (NiCo), aluminum, silver, zinc, nickel, copper or a mixture of these.
Le bouclier de protection 14 est selon un autre exemple en matériau céramique. 11 est destiné à protéger le bord d’attaque 12a des chocs extérieurs. Le bouclier de protection 14 présente une forme allongée en forme de dièdre. Comme mieux visible sur la figure 3, le bouclier de protection 14 présente une section transversale en forme de V ou de U. Le bouclier de protection 14 comprend une première ailette latérale 14a et une seconde ailette latérale 14b reliée à la première ailette latérale 14a par une âme 14j. Les première et seconde ailettes latérales 14a, 14b définissent entre elles une cavité dans laquelle le bord d’attaque 12a est agencé. The protective shield 14 is according to another example made of ceramic material. 11 is intended to protect the leading edge 12a from external shocks. The protective shield 14 has an elongated dihedral shape. As better visible in Figure 3, the protective shield 14 has a V- or U-shaped cross section. The protective shield 14 comprises a first side fin 14a and a second side fin 14b connected to the first side fin 14a by a soul 14d. The first and second side fins 14a, 14b define between them a cavity in which the leading edge 12a is arranged.
La première ailette latérale 14a présente une première extrémité longitudinale libre et la seconde ailette latérale 14b présente une seconde extrémité longitudinale libre qui sont opposées à l’âme 14j. Les extrémités longitudinales libres s’étendent le long de la pale 12. Les extrémités longitudinales libres s’étendent respectivement sur la face intrados 12i et la face extrados 12b de la pale 12. The first lateral fin 14a has a first free longitudinal end and the second lateral fin 14b has a second free longitudinal end which are opposite the core 14j. The free longitudinal ends extend along the blade 12. The free longitudinal ends extend respectively on the intrados face 12i and the extrados face 12b of the blade 12.
Avantageusement, l’épaisseur du bouclier de protection 14 est variable. L’épaisseur de l’âme 14j est supérieure aux épaisseurs des première et seconde ailettes latérales 14a, 14b. Avantageusement, l’épaisseur des première et seconde ailettes latérales 14a, 14b est décroissante en direction du bord de fuite 12b de la pale 12. Les première et seconde ailettes latérales 14a, 14b sont effilées en direction du bord de fuite 12b de la pale 12. Advantageously, the thickness of the protective shield 14 is variable. The thickness of the core 14j is greater than the thicknesses of the first and second side fins 14a, 14b. Advantageously, the thickness of the first and second side fins 14a, 14b decreases towards the trailing edge 12b of the blade 12. The first and second side fins 14a, 14b are tapered towards the trailing edge 12b of the blade 12. .
Alternativement, et de manière non représentée, le bouclier de protection 14 est agencé sur le bord de fuite 12b. Selon encore une autre alternative non représentée, l’aube 11 comprend deux boucliers de protection 14 agencés respectivement sur le bord d’attaque 12a et le bord de fuite 12b. Alternatively, and not shown, the protective shield 14 is arranged on the trailing edge 12b. According to yet another alternative not shown, the blade 11 comprises two protective shields 14 arranged respectively on the leading edge 12a and the trailing edge 12b.
Le bouclier de protection 14 est de manière très avantageuse formée sur la pale 12 par projection thermique. The protective shield 14 is very advantageously formed on the blade 12 by thermal spraying.
L’aube 11 comprend en outre une couche de liaison 16 agencée entre la paleThe blade 11 further comprises a connecting layer 16 arranged between the blade
12 et le bouclier de protection 14. La couche de liaison 16 permet d’assurer l’adhérence du bouclier de protection 14 sur la pale 12 sans endommager la pale 12. La couche de liaison 16 est en matériau polymérique. Le matériau polymérique est avantageusement choisi parmi les polymères thermodurcissables tels qu’un polymère époxyde, silicone ou polyuréthane ou les polymères thermoplastiques ou encore un mélange de ceux-ci. Le polymère époxyde est par exemple le matériau commercial Redux® 322 de la société HEXCEL. 12 and the protective shield 14. The bonding layer 16 ensures adhesion of the protective shield 14 on the blade 12 without damaging the blade 12. The connecting layer 16 is made of polymeric material. The polymeric material is advantageously chosen from thermosetting polymers such as an epoxy, silicone or polyurethane polymer or thermoplastic polymers or even a mixture of these. The epoxy polymer is for example the commercial material Redux® 322 from the company HEXCEL.
La couche de liaison 16 est typiquement sous la forme d’un film à base de l’un des matériaux cités. Le film est par exemple le film commercial AF191 ou AF3109 de la société 3M. Avantageusement, la couche de liaison 16 présente une épaisseur comprise entre 50 pm et 500 pm, encore plus avantageusement comprise entre 80 pm et 400 pm. The bonding layer 16 is typically in the form of a film based on one of the materials mentioned. The film is for example the commercial film AF191 or AF3109 from the company 3M. Advantageously, the connecting layer 16 has a thickness of between 50 pm and 500 pm, even more advantageously between 80 pm and 400 pm.
Un procédé de fabrication de l’aube 11 selon l’invention va maintenant être décrit en référence à la figure 5. A method of manufacturing the blade 11 according to the invention will now be described with reference to Figure 5.
Le procédé comprend les étapes chronologiques suivantes: The process includes the following chronological steps:
(a) fournir la pale 12, (a) supply blade 12,
(b) agencer la couche de liaison 16 sur la pale 12 (b) arrange the bonding layer 16 on the blade 12
(c) former le bouclier de protection 14 sur la pale 12 par projection thermique,(c) forming the protective shield 14 on the blade 12 by thermal spraying,
(d) traiter thermiquement la couche de liaison 16, (d) heat treating the bonding layer 16,
(e) optionnellement, usiner le bouclier de protection 14. (e) optionally, machine the protective shield 14.
L’étape (a) peut être réalisée par moulage tel qu’un moulage par transfert de résine connu sous l’acronyme RTM pour « Resin Transfer Molding » en langue anglaise ou un drapage. Step (a) can be carried out by molding such as resin transfer molding known by the acronym RTM for “Resin Transfer Molding” in English or draping.
L’étape (b) peut être réalisée par drapage du film, ou par application manuelle du matériau de la couche de liaison 16. Step (b) can be carried out by draping the film, or by manually applying the material of the bonding layer 16.
Le procédé de projection thermique de l’étape (c) est par exemple un procédé de projection par flamme par exemple par flamme d'oxygène à haute vitesse (HVOF pour « High Velocity Oxy-Fuel » en langue anglaise), par arc-fil, par suspension, par plasma d’arc, cold spray ou tout autre procédé de projection thermique applicable. The thermal spraying process of step (c) is for example a flame spraying process, for example by high speed oxygen flame (HVOF for “High Velocity Oxy-Fuel” in English), by arc-wire , by suspension, by arc plasma, cold spray or any other applicable thermal spraying process.
La projection thermique est réalisée avec une poudre comprenant des particules dont au moins 90% de ces particules présentent une taille (d90) comprise entre 5 pm et 200 pm, avantageusement comprise entre 10 pm et 150 pm et préférentiellement dont au plus 10% des particules présentent une taille (d10) comprise entre 0,05 pm et 50 pm, avantageusement comprise entre 0,1 pm et 20 pm. Thermal spraying is carried out with a powder comprising particles of which at least 90% of these particles have a size (d90) between 5 pm and 200 pm, advantageously between 10 pm and 150 pm and preferably of which at most 10% of the particles have a size (d10) between 0.05 pm and 50 pm, advantageously between 0.1 pm and 20 p.m.
En particulier, dans le cas d’une projection d’une projection plasma à pression atmosphérique (APS), la poudre comprend des particules dont au moins 90% de ces particules présentent une taille (d90) de 110 pm et dont au plus 10% des particules présentent une taille (d10) de 10 pm. In particular, in the case of a projection of an atmospheric pressure plasma projection (APS), the powder comprises particles of which at least 90% of these particles have a size (d90) of 110 pm and of which at most 10% particles have a size (d10) of 10 pm.
Dans le cas d’une projection plasma de suspensions (SPS), la poudre est sous la forme d’une suspension comprenant des particules dont au moins 90% de ces particules présentent une taille (d90) de 10 pm et dont au plus 10% des particules présentent une taille (d10) de 0,1 pm. In the case of plasma projection of suspensions (SPS), the powder is in the form of a suspension comprising particles of which at least 90% of these particles have a size (d90) of 10 pm and of which at most 10% particles have a size (d10) of 0.1 pm.
Avantageusement, les particules sont des particules de métal tel que de l’aluminium, de l’argent, du zinc, du nickel, du titane, du cuivre, un alliage de fer, un alliage métallique ou des particules de céramique tel que des particules non oxyde comme du carbure de silicium, ou des particules d’oxyde tel qu’un oxyde d’aluminium, un oxyde de zirconium, un oxyde de silicium, ou encore un mélange des particules. Advantageously, the particles are particles of metal such as aluminum, silver, zinc, nickel, titanium, copper, an iron alloy, a metal alloy or ceramic particles such as particles non-oxide such as silicon carbide, or oxide particles such as aluminum oxide, zirconium oxide, silicon oxide, or even a mixture of particles.
L’étape de projection thermique est réalisée sur une couche de liaison 16 homogène ce qui contribue à la bonne adhérence du bouclier de protection 14 sur toute la surface de la couche de liaison 16. The thermal spraying step is carried out on a homogeneous bonding layer 16, which contributes to good adhesion of the protective shield 14 over the entire surface of the bonding layer 16.
L’étape (c) de projection thermique est réalisée le long du bord d’attaque 12a et/ou le long du bord de fuite 12b de la pale 12. Thermal projection step (c) is carried out along the leading edge 12a and/or along the trailing edge 12b of the blade 12.
L’étape (d) permet la polymérisation de la couche de liaison 16 et la consolidation de l’interface entre la couche de liaison 16 et la couche fonctionnelle formée par le revêtement 14. Step (d) allows the polymerization of the bonding layer 16 and the consolidation of the interface between the bonding layer 16 and the functional layer formed by the coating 14.
Elle peut être réalisée par chauffage à une température comprise entre 100°C et 200°C, avantageusement comprise entre 120°C et 190°C, encore plus avantageusement comprise entre 140°C et 190°C. L’étape (d) est préférentiellement réalisée pendant une durée supérieure à 10 min, supérieure à 15 min, supérieure à 20 min, supérieure à 30 min encore plus préférentiellement entre 45 min et 200 min. L’aube 11 est par exemple placée dans un dispositif de chauffage tel qu’une étuve, un four ou un autoclave.It can be carried out by heating to a temperature between 100°C and 200°C, advantageously between 120°C and 190°C, even more advantageously between 140°C and 190°C. Step (d) is preferably carried out for a duration greater than 10 min, greater than 15 min, greater than 20 min, greater than 30 min even more preferably between 45 min and 200 min. The blade 11 is for example placed in a heating device such as an oven, an oven or an autoclave.
L’étape (e) d’usinage peut être un usinage chimique ou un usinage mécanique tel qu’un découpage. Selon un mode de réalisation particulièrement avantageux de l’invention illustré sur la figure 6, le procédé comprend entre les étapes (b) et (c) une étape (f) de pré-traitement thermique de la couche de liaison 16. Cette étape peut être réalisée par chauffage de la couche de liaison 16 à une température inférieure ou égale à 150 °C pour une pré-polymérisation, avantageusement inférieure ou égale à 130 °C. Cette étape de prétraitement thermique permet avantageusement d’éviter la perte de la couche de liaison 16 lors de l’étape (c) de projection thermique. Machining step (e) can be chemical machining or mechanical machining such as cutting. According to a particularly advantageous embodiment of the invention illustrated in Figure 6, the method comprises between steps (b) and (c) a step (f) of thermal pre-treatment of the bonding layer 16. This step can be carried out by heating the bonding layer 16 to a temperature less than or equal to 150°C for pre-polymerization, advantageously less than or equal to 130°C. This thermal pretreatment step advantageously makes it possible to avoid the loss of the bonding layer 16 during step (c) of thermal spraying.
Cette même étape (f) peut être réalisée à une température inférieure égale à 100 °C pour augmenter uniquement la pégosité. Cette étape peut être réalisée dans une étuve ou un autoclave ou un four. Cette étape permet d’augmenter la force d’adhérence à l’interface de la couche de liaison 16 et du bouclier de protection 14. This same step (f) can be carried out at a temperature lower than 100°C to only increase the tackiness. This step can be carried out in an oven or an autoclave or an oven. This step makes it possible to increase the adhesion force at the interface of the bonding layer 16 and the protective shield 14.

Claims

REVENDICATIONS
1. Procédé de fabrication d’une aube (11 ) pour une turbomachine (1 ) d’aéronef, le procédé comprenant les étapes chronologiques suivantes :1. Process for manufacturing a blade (11) for an aircraft turbomachine (1), the process comprising the following chronological steps:
(a) fournir une pale (12) comprenant une face extrados (12e) et une face intrados (12i) reliées par un bord d’attaque (12a) et un bord de fuite (12b), la pale (12) comprenant un matériau composite, (a) providing a blade (12) comprising an extrados face (12e) and an intrados face (12i) connected by a leading edge (12a) and a trailing edge (12b), the blade (12) comprising a material composite,
(b) agencer une couche de liaison (16) sur la pale (12), la couche de liaison (16) comprenant un matériau polymérique, le procédé étant caractérisé en ce qu’il comprend en outre les étapes chronologiques suivantes après l’étape (b) : (b) arranging a bonding layer (16) on the blade (12), the bonding layer (16) comprising a polymeric material, the method being characterized in that it further comprises the following chronological steps after step (b):
(c) former un bouclier de protection (14) sur la pale (12) par projection thermique, (c) forming a protective shield (14) on the blade (12) by thermal spraying,
(d) traiter thermiquement la couche de liaison (16). (d) heat treating the bonding layer (16).
2. Procédé selon la revendication précédente, caractérisé en ce que la projection thermique est réalisée avec une poudre comprenant des particules métalliques, céramiques ou un mélange de celles-ci. 2. Method according to the preceding claim, characterized in that the thermal spraying is carried out with a powder comprising metallic or ceramic particles or a mixture thereof.
3. Procédé selon la revendication précédente, caractérisé en ce qu’au moins 90% des particules présentent une taille (d90) comprise entre 5 pm et 200 pm, avantageusement comprise entre 10 pm et 150 pm. 3. Method according to the preceding claim, characterized in that at least 90% of the particles have a size (d90) between 5 pm and 200 pm, advantageously between 10 pm and 150 pm.
4. Procédé selon la revendication précédente, caractérisé en ce qu’au plus 10% des particules présentent une taille (d10) comprise entre 0,05 pm et 50 pm, avantageusement comprise entre 0,1 pm et 20 pm. 4. Method according to the preceding claim, characterized in that at most 10% of the particles have a size (d10) between 0.05 pm and 50 pm, advantageously between 0.1 pm and 20 pm.
5. Procédé selon l’une quelconque des revendications précédentes, caractérisé en ce que la couche de liaison (16) présente une épaisseur comprise entre 50 pm et 500 pm, avantageusement entre 80 pm et 400 pm. 5. Method according to any one of the preceding claims, characterized in that the connecting layer (16) has a thickness of between 50 pm and 500 pm, advantageously between 80 pm and 400 pm.
6. Procédé selon l’une quelconque des revendications précédentes, caractérisé en ce que l’étape (d) est réalisée à une température comprise entre 100 °C et 200 °C, avantageusement entre 140 °C et 190 °C. 6. Method according to any one of the preceding claims, characterized in that step (d) is carried out at a temperature between 100 °C and 200 °C, advantageously between 140 °C and 190 °C.
7. Procédé selon l’une quelconque des revendications précédentes, caractérisé en ce qu’à l’étape (d) l’aube (11 ) est placée dans un dispositif de chauffage tel qu’une étuve, un four ou un autoclave. 7. Method according to any one of the preceding claims, characterized in that in step (d) the blade (11) is placed in a heating device such as an oven, an oven or an autoclave.
8. Procédé selon l’une quelconque des revendications précédentes, caractérisé en ce qu’il comprend entre les étapes (b) et (c) une étape (f) de pré traitement thermique de la couche de liaison (16). 8. Method according to any one of the preceding claims, characterized in that it comprises, between steps (b) and (c), a step (f) of pre-heat treatment of the bonding layer (16).
9. Procédé selon la revendication précédente, caractérisé en ce que l’étape (f) est réalisée à une température inférieure ou égale à 150 °C, avantageusement inférieure ou égale à 130 °C, ou avantageusement encore inférieure à 100°C. 9. Method according to the preceding claim, characterized in that step (f) is carried out at a temperature less than or equal to 150°C, advantageously less than or equal to 130°C, or advantageously even less than 100°C.
10. Procédé selon l’une quelconque des revendications précédentes, caractérisé en ce qu’il comprend, après l’étape (d), une étape (e) d’usinage du bouclier de protection (14). 10. Method according to any one of the preceding claims, characterized in that it comprises, after step (d), a step (e) of machining the protective shield (14).
PCT/FR2023/051764 2022-11-14 2023-11-09 Method for manufacturing a vane WO2024105324A1 (en)

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FRFR2211788 2022-11-14
FR2211788A FR3141878A1 (en) 2022-11-14 2022-11-14 METHOD FOR MANUFACTURING A BLADE

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3008109A1 (en) 2013-07-03 2015-01-09 Snecma METHOD FOR PREPARING THE REMOVAL OF A METALLIC COATING THROUGH THERMAL PROJECTION ON A SUBSTRATE
US20160305442A1 (en) 2015-04-15 2016-10-20 United Technologies Corporation Abrasive Tip for Composite Fan Blades

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3008109A1 (en) 2013-07-03 2015-01-09 Snecma METHOD FOR PREPARING THE REMOVAL OF A METALLIC COATING THROUGH THERMAL PROJECTION ON A SUBSTRATE
US20160305442A1 (en) 2015-04-15 2016-10-20 United Technologies Corporation Abrasive Tip for Composite Fan Blades

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